Green Belt Body of Knowledge

Foundations & Organizational Alignment

• Value of Six Sigma: History and purpose. Quality philosophies of Juran, Deming, Shewhart, Ishikawa.
• Organizational Goals: How Lean Six Sigma supports strategic goals.
• Organizational Drivers & Metrics: Profitability, market share, customer satisfaction, Balanced Scorecard.
• Lean Principles: Value, flow, 7 wastes, and 3Ms (Muda, Mura, Muri).
• Design for Six Sigma (DFSS): Overview of DMADV and IDOV approaches.

Define Phase

• Project Identification: Selection process, stakeholder analysis.
• Voice of Customer & Business: CTQ Tree, Cost of Poor Quality.
• Project Charter & SIPOC: Key tools to initiate projects.

Team Management & Planning

• Team Communication: Communication plans, team dynamics.
• Roles & Responsibilities: Brainstorming, NGT, Multi-voting.
• Planning Tools: Affinity, tree, interrelationship diagrams, PDPC, matrix diagrams, activity networks.

Measure Phase

• Basic Statistics: Descriptive & inferential, CLT, distributions.
• Probability: Independent/mutually exclusive events, permutations & combinations.
• Process Characteristics: Flow metrics, process mapping tools.
• Data Collection: Types, scales, sampling, methods.
• MSA: Bias, linearity, stability, Gage R&R, P/T Ratio.
• Process Capability: Cp, Cpk, Pp, Ppk, DPMO, PPM, ST vs LT capability.

Analyze Phase

• Relationships Between Variables: Correlation, linear regression.
• Hypothesis Testing: Means, variances, proportions, ANOVA, chi-square.
• FMEA: PFMEA and DFMEA techniques.
• Other Tools: Root Cause Analysis, Waste Analysis, Why-Why.

Improve & Control Phase

• DOE (Design of Experiments): Basics, main & interaction effects.
• Lean Tools: 5S, Kanban, Standard Work, SMED, Kaizen, Continuous Flow.
• Pilot Implementation: Strategies for rollout.
• SPC Basics: Variable selection, control chart types, subgrouping, chart analysis.
• Other Controls: TPM, Poka Yoke, Visual controls, Control Plan.

Black Belt Body of Knowledge

Module 1: Introduction

• Fundamentals: Six Sigma, Lean, Continuous Improvement Methodologies
• Business Systems & Processes: Strategic planning, Deployment
• Leadership: Roles, Roadblocks, Change management
• Organizational Process Management: Stakeholder analysis, Benchmarking, Financial & performance measures
• Team Management: Formation, Facilitation, Dynamics, Training

Module 2: Define Phase

• Voice of Customer (VOC): Identification, Data collection, Requirements
• Business Case & Project Charter: Scope, Goals, Performance metrics, Review
• Project Management Tools: Gantt chart, WBS, RACI, Toll-gate reviews
• Analytical Tools: Affinity diagrams, Tree diagrams, Prioritization matrices, Matrix & Activity network diagrams

Module 3: Measure Phase

• Process Characteristics: Flow metrics, Analysis tools
• Data Collection: Data types, Scales, Sampling, Collection methods
• Measurement Systems: MSA, Organizational-level measurement, Metrology
• Basic Statistics: Descriptive statistics, CLT, Graphical methods, Valid conclusions
• Probability: Core concepts and distributions
• Process Capability: Cp, Cpk, Pp, Ppk, Non-normal data, Attributes data, ST vs LT capability

Module 4: Analyze Phase

• Relationships Between Variables: Correlation, Regression, Multivariate tools
• Hypothesis Testing: Means, Variances, ANOVA, Chi-square, Nonparametric tests, Practical vs statistical significance
• FMEA: Failure Modes for process and design
• Other Tools: Gap Analysis, RCA, Waste Analysis

Module 5: Improve Phase

• DOE: Terminology, Design planning, One-factor, Fractional & Full factorial experiments
• Lean Methods: Waste elimination, Cycle time, Kaizen, TOC, OEE, Pilot implementation

Module 6: Control Phase

• SPC: Objective, Variable selection, Subgrouping, Control chart selection & analysis
• Other Controls: TPM, Visual controls
• Maintain Controls: Control plan
• Sustain Improvements: Documentation, Training, Evaluation, Lessons learned

Module 7: Design for Six Sigma (DFSS)

• Common DFSS Methodologies: DMADV, IDOV
• Design for X (DFX): Reliability, Maintainability, Safety, Cost, etc.
• Robust Design: Methods to ensure product/process stability